Ball Roller Tool for Die-Free Sheet Metal Forming
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Solution Overview
Problem
The existing methods for sheet metal part forming, such as stamping, are costly and time-consuming due to the need for extensive tooling and dies, and are not adaptable to design and material changes.
Innovation Solution
The use of robotic systems equipped with roller tools and machine learning-based control systems to form sheet metal parts by applying incremental deformations, reducing the need for traditional tooling and enabling faster prototyping and customization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional stamping with dies is used, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces traditional mechanical stamping dies with a robotic system that uses a roller tool to apply localized forces to the sheet metal. The robotic arm with force control substitutes the complex mechanical die system, achieving forming through controlled incremental deformation rather than bulk stamping.
Solution Approach 2:
The patent changes the forming parameters by applying small incremental forces through the roller tool rather than large single-stage forces from dies. The system controls force magnitude, application point, and duration dynamically, allowing complex shapes to be formed through multiple small deformations instead of requiring complex die geometries.
2Manufacturing precision
If traditional stamping with dies is used, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
The patent introduces dynamics by using a robotic system that can adapt its motion and force application in real-time. The robotic arm can move the roller tool to different positions and adjust forming parameters dynamically, eliminating the need for pre-fabricated dies and enabling rapid reconfiguration for different part designs.
Solution Approach 2:
The system achieves time savings by dynamically changing forming parameters (force, position, duration) through software control rather than physically changing dies. This allows rapid transition between different part geometries and materials without the time-consuming process of fabricating and changing physical tooling.
3Adaptability or versatility
If traditional stamping with dies is used, then adaptability is improved for specific designs, but ease of manufacture worsens due to cost and time
Solution Approach 1:
The robotic roller tool system serves multiple functions: it can form various sheet metal geometries, work with different materials, and adapt to changing design requirements. This single universal system replaces the need for multiple specialized dies, improving ease of manufacture while maintaining design adaptability through software control.
Solution Approach 2:
The system achieves adaptability through parameter changes rather than physical tooling changes. By modifying force magnitude, application location, and deformation sequence through software, the system can accommodate different designs and materials, making manufacturing easier and more flexible compared to dedicated dies.
4Device complexity
If robotic roller tool is used, then device complexity is reduced, but force control precision must be improved
Solution Approach 1:
The patent implements feedback control by using force sensors on the roller tool to monitor applied forces in real-time. The system compares measured forces with target forces and adjusts robotic arm commands accordingly, ensuring precise force application despite the simplicity of the roller tool mechanism.
Solution Approach 2:
The patent replaces complex mechanical force transmission mechanisms with a robotic system that uses sensors and software control to achieve precise force application. The robotic arm with integrated force control substitutes mechanical force multiplication mechanisms, achieving precision through electronic control rather than mechanical design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces the time and cost of manufacturing sheet metal parts, enhances product development, and allows for rapid customization and 'lightweighting' strategies in industries like aerospace and automotive.
Implementation Method 1
the socket configured to, responsive to the ball being pressed onto the surface above a threshold pressure, deform such that contact area of the ball with the socket increases
Implementation Method 2
the socket configured to, responsive to the ball being pressed onto the surface above a threshold pressure, deform such that contact area of the ball with the socket increases
Data Source
AI summary
A system can form a part in an initial geometry into a desired geometry. The system may include a roller tool and a robot arm that: (a) presses the roller tool onto a surface of the part and (b) moves the pressed roller tool along the surface of the part to form the desired geometry. The roller tool includes a ball and a support with a socket that receives the ball and enables the ball to rotate in the socket. The support may include a channel configured to carry fluid through the support toward the ball or away from the ball. The socket may deform such that contact area of the ball with the socket increases in response to the ball being pressed onto the surface above a threshold pressure.